Method for forming an insulated electrical connection

ABSTRACT

AN APPARATUS IS PROVIDED FOR FORMING AN INSULATED ELECTRICAL CONNECTION. AN ELECTRICAL TERMINAL HAVING AN OPEN U-SHAPED FERRULE-FORMING PORTION IS FED TO A FIRST CRIMPING STATION. THE STRIPPED END OF AN INSULATED ELECTRICAL CONDUCTOR IS INSERTED INTO THE FERRULE-FORMING PORTION AND THE TERMINAL IS CRIMPED TO THE CONDUCTOR. AN OPEN U-SHAPED INSULATING MEMBER IS FED TO A SECOND CRIMPING STATION. THE TERMINAL AND CONDUCTOR PREVIOUSLY JOINED ARE TRANSFERRED TO THE SECOND CRIMPING STATION IN OVERLYING RELATIONSHIP WITH THE INSULATING MEMBER. THE INSULATING MEMBER IS THEN CRIMPED AROUND THE TERMINAL AND CONDUCTOR.

Feb. 16, 1971 R LAU ETAL 3,562,904

METHOD FOR FORMING AN INSULATED ELECTRICAL CONNECTION Original FiledSept. 23, 1965 6 Sheets-Sheet 1 Feb.-16, 1971 v R. LAU m1 3,562,904

METHOD FOR FORMING AN INSULATED ELECTRICAL CONNECTION Original FiledSept. 23, 1965 6 Sheets-Sheet 2 :1 I m 5 31 :3 3, 3* :2 f)

Feb. 16, 1971 LAU ETIAL METHOD FOR FORMING AN INSULATED ELECTRICALCONNECTION 6 Sheets-Sheet 3 Original Filed Sept. 23, 1965 :5 5m mom Nowon \A Feb. 16,. 1971 R. LAU ETAL 3,562,904

METHOD FOR FORMING AN INSULATED ELECTRICAL CONNECTION 6 Sheets-Sheet 4.

Original Filed Sept. 23, 1965 METHOD FOR FORMING AN INSULATED ELECTRICALCONNECI [ON 6 Sheei s-Sheet 5 Original Filed Sept. 23, 1965 Feb. 16,1971 R R LAU ET AL 3,562,904

' METHOD FOR FORMING AN INSULATED ELECTRICAL CONNECTION Original FiledSept. 23, 1965 6 Sheets-Sheet 6 United States Patent Office 3,562,904Patented Feb. 16, 1971 3,562,904 METHOD FOR FORMING AN INSULATEDELECTRICAL CONNECTION Ralph Rupp Lau, Harrisburg, Pa., and Gilbert CarlSitz, Richardson, Tern, assignors to AMP Incorporated, Harrisburg, Pa.

Original application Sept. 23, 1965, Ser. No. 489,558, now Patent No.3,386,153. Divided and this application Feb. 8, 1968, Ser. No. 704,048

Int. Cl. H01r 43/00 US. Cl. 29628 2 Claims ABSTRACT OF THE DISCLOSURE Anapparatus is provided for forming an insulated electrical connection. Anelectrical terminal having an open U-shaped ferrule-forming portion isfed to a first crimping station. The stripped end of an insulatedelectrical conductor is inserted into the ferrule-forming portion andthe terminal is crimped to the conductor. An open U-shaped insulatingmember is fed to a second crimping station. The terminal and conductorpreviously joined are transferred to the second crimping station inoverlying relationship with the insulating member. The insulating memberis then crimped around the terminal and conductor.

This application is a division of our prior copending application Ser.No. 489,558, filed Sept. 23, 1965 now U.S. Pat. No. 3,386,153.

In the electrical connection'field there have been numerous attempts topre-insulate an electrical terminal wherein both the terminal ferruleand the insulating member are of open U-shaped configuration. Most suchattempts, prior to this invention, have been unsuccessful for variousreasons, some of which will become apparent as this discussion proceeds.

At present, when it is desired to pre-insulate a terminal having an openU-shaped ferrule-forming portion, it is the practice to take such aterminal and secure thereto a strip of insulating material. Theterminal, with the insulating material thus secured, is then placedbetween the jaws of a crimping tool. An electrical conductor is theninserted into the space formed by the open U, and the jaws of thecrimping tool are then closed so as to accomplish in one operation thecrimping of both the terminal and the insulating member to theelectrical conductor. The force exerted by the crimping tool is carriedthrough the insulating member to the terminal, this being necessarybecause the terminal does not come into direct contact with the crimpingtool. Examples of this type of operation are disclosed in US. Pats. No.2,786,191, granted to W. F. Broske, No. 2,845,606, granted to G. A.Fuller, and No. 3,048,650, granted to J. W. Allen et al.

The present invention provides several distinct advantages over theprior art above referred to. In the prior art devices the pressureapplied during the crimping operation must be held within close limits.The pressure must be great enough to accomplish an eliective crimp ofthe ferrule to the conductor but at the same time the pressure must beheld below that point which would cause rupturing of the relativelyfragile insulating material. This problem is avoided by the presentinvention wherein the crimping of the insulating member is accomplishedin a separate operation from the crimping of the ferrule, therebypermitting relatively high pressure during the ferrule crimpingoperation and relatively low pressure during the insulating membercrimping operation. Further, as will become apparent, the two stageoperation of the present invention is accomplished with no loss of timeas compared with the single stage operation of the prior known devices.

In the single stage operation there is a limited number of materialswhich can be used for the insulating material because such material mustbe capable of withstanding high crimping pressure without rupturing andthe material must be capable of transmitting the forces from thecrimping tool to the ferrule. In the present invention these propertiesneed not be possessed by the insulating material, the only essentialrequirement being that the material is an electrical insulator.

Another drawback of the known devices is that the terminals must bespecially constructed and adapted to receive the insulating member. Incontrast the present invention is designed for use with standardpresently available terminals.

Also, the prior known devices require a step of securing the insulatingmaterial to the terminal prior to the crimping operation. This step isnot necessary in practicing the present invention.

It is therefore an object of the present invention to provide a methodan apparatus for forming an insulated electrical connection whileavoiding the drawbacks of the known devices above referred to.

Another object is to provide for the pre-insulating of standardterminals.

A further object is to provide a method and apparatus for forming aninsulated electrical connection utilizing high crimping pressure on theterminal ferrule and low crimping pressure on the insulating member.

A still further object is to provide a machine and method for performingtwo diverse crimping operations in the same time as now required for asingle crimping operation.

Other objects and attainments of the present invention will becomeapparent to those skilled in the art upon a reading of the followingdetailed description when taken in conjunction with the drawings inwhich there is shown and described an illustrative embodiment of theinvention; it is to be understood, however, that this embodiment is notintended to be exhaustive nor limiting of the invention but is given forpurpose of illustration in order that others skilled in the art mayfully understand the invention and the principles thereof and the mannerof applying it in practical use so that they may modify it in variousforms, each as may be best suited to the conditions of a particular use.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings, in which likereference numerals refer to like parts:

FIG. 1 is a perspective view of the apparatus forming a preferredembodiment of the invention;

FIG. 2 is a side elevation, partly in section and taken along line 22 ofFIG. 3;

FIG. 3 is a front elevation, partly in section and taken along line 33of FIG. 2;

FIG. 4 is a view similar to FIG. 2 but showing the ram in its loweredposition;

FIG. 5 is a sectional view taken along the line 5-5 of FIG. 3;

FIG. 6 is a fragmentary view showing the crimping heads and movableshear blades as seen when looking along line 66 of FIG. 2 in thedirection of the arrows;

FIG. 7 is a sectional view taken along the line 77 of FIG. 6 and showingthe adjustment means for one of the crimping heads;

*FIG. 8 is an exploded perspective view of the movable shear assembly;

:FIG. 9 is an exploded perspective view of the insulation strip feedassembly;

FIG. is a fluid flow diagram showing schematically the power system ofthe invention; and

FIG. 11 is a perspective view showing the completed electricalconnection made in accordance with the teachings of this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to FIG. 1 theapparatus comprises a first crimping and shearing station A, a secondcrimping and shearing station B, a terminal feed assembly C, aninsulation feed assembly D, and a transfer assembly E. Briefly stated,the operation is such that a strip of electrical terminals is fed byassembly C to station A. An electrical conductor is positioned atstation A above the terminal at the lead end of the strip. The parts arethen crimped and the terminal is severed from its strip. A strip ofinsulating members is fed by assembly D to station B. Assembly Etransfers the crimped terminal and conductor from station A to station Ein a position above the insulating member at the lead end of the strip.The insulating member is then severed from its strip and crimped to theterminal and conductor thus forming a completed insulated electricalconnection.

The various parts and operation of the device will now be described indetail.

The terminal feed assembly C is best illustrated in FIGS. 1, 2 and 4. Tothe frame 20 of the machine is secured a mounting plate 22. An L-shapedbracket 24 is secured to plate22 and carries thereon a spacing block 26secured to bracket 24 by means of a screw 28. Secured to block 26, bymeans of set screws (not shown) is a plate 30 along the upper surface ofwhich the strip of terminals will slide. A pair of guide members 32 and34 are secured to plate 30 by means of four screws 36, only two of whichare shown. These guide members, together with plate 30, form a channel37 to define the path of movement of the terminal strip. Secured toguide member 34 by means of one of the screws 36 is a bracket 38 forsuspending the upper portion of the feed assembly. A double-acting fluidcylinder 40 is secured to bracket 38 and carries at its rear portion abracket 42 to which is secured the terminal strip guide 44. The guide 44functions to lead the strip into channel 37 from a supply source (notshown). The cylinder 40 has a piston member 46 which adjustably carriesa stop member 48 for limiting the retracting motion of the piston. Thestop 48 has a bifurcated end 50 which slides along a rod member 52secured to a bracket 38. The rod 52 serves to prevent any rotativemovement of piston 46. A forked member 54 is adjustably secured topiston 46 and is held in adjusted position by a nut 56. The forked endsof member 54 receive a pin 58 which pivotally supports a feed finger'60. The finger 60 is biased into engagement with the upper surface ofguide members 32 and 34 by means of a spring 62 wrapped around pin 58. Astrip of terminals -64, made up of individual terminals 66, 68, 70 ispositioned in channel 37 and is fed therealong by engagement of the feedfinger 60 with the upstanding barrel portion of the terminal, as bestseen in FIG. 2. FIG. 2 shows finger 60 at the forward end of its strokeafter having advanced terminal 66 into position at station A. FIG. 4shows finger 60 at the rearward end of its stroke moving into positionbehind the barrel of terminal 70 to thereby move terminal 68 intoposition at station A upon the next forward stroke of finger 60.

At the forward end of feed assembly C is the crimping and cuttingstation A which will now be described with particular reference to FIGS.1, 2 and 3. A ram 72, driven by suitable means, not shown, has at itsend a mounting block 74 formed integrally with said ram. Secured toblock 74 by means of a bolt 76 and lock nuts 78 is a first crimping head80. Also held in place by bolt 76 and nuts 78 is a shear blade 82. Theblade 82 has a lower cutting surface 84 and a recessed portion 86. Theupper surface of blade 82 is relieved at 88 (see FIG. 6) to permitlimited pivotal movement of the blade about bolt 76. The blade isnormally biased into a vertical position by means of a leaf spring 90secured to block 74 by set screws 92 and 94. Secured to plate 22 is afirst crimping die 96 for cooperation with crimping head 80. Adjacent todie 96 is a fixed shear member 9 8. A second fixed shear member isspaced from member 98 by a pair of spacers 102, one of which is shown,and as shown in FIG. 4 the shear blade 82 moves between members 98 and100 to sever the leading terminal from the strip. The shear face ofmember 100 is recessed at its lower end as indicated at 104 to provideclearance of the material severed from the terminal strip. Also thebracket 24 has a central groove 106 permitting the discharge of thesevered material 108, see FIG. 4.

The insulating member feed assembly D will now be described withreference to FIGS. 3, 8 and 9. A U-shaped block 110 is secured to plate22. A pair of gibs 112 and 114 are positioned in parallel relationshipon the upper surface of a guide plate 116. The gibs 112, and '114, theplate 116, and the block 110 are secured together by a pair of setscrews 118. A double-acting fluid cylinder is secured to plate 116 by amounting block 122. The piston 124 of cylinder 120 is provided with athreaded portion 126 to adjustably hold a fork member 128. A nut -130secures member 128 in adjusted position. A feed finger 132 is pivotallysecured to member 128 by pin-134. Encircling pin 134 is a spring 136which biases finger 132 counterclockwise as seen in FIG. 3. Finger 132is provided at its end with a pair of lugs 138 which ride in slots 140in plate 116. The lugs 138 will engage cross pieces 142 on theinsulation strip to feed the insulating members to station B. Flanges144 on gibs 112 and 114 overlie the slots 140 to maintain pieces 142 inengagement with lugs 13 8. The gibs 112 and 114 are further providedwith diagonal slots 146 within which are located spring strips 148secured to the gibs by screws 150. The strips 148 prevent retrogrademovement of the insulation strip upon retraction of feed finger 132. Atypical insulation strip is shown in FIG. 8 and indicated generally at152. The strip 152 is of ladder configuration and consists of U-shapedinsulating members 154, 156, 158 secured by the cross pieces 142 tocarrier strips 160. If the material of which the insulating members aremade is sufiiciently rigid only one carrier strip need be used. In suchcase only one of the lugs 138 of feed finger 132 will be used.

Suitable insulating materials are disclosed in the following U.S. Pats.:2,7l5,716; 2,786,191; 2,806,214; 2,807,- 792 and 2,974,400.

Crimping and severing station B is best shown in FIGS. 1, 3 and 8. Asecond crimping head 162 is secured to block 74 adjacent to the firstcrimping head 80. The head 162 performs the crimp on the insulatingmember. Since the material of the insulating members may vary, differentcrimping pressures are sometimes desired. The crimping pressure iscontrolled by the spacing between the movable crimping head and thefixed crimping die. To allow for varying the spacing of the crimpingtools, head 162 is secured to block 74 by a screw 164 extending throughan elongated slot 166 in head 162 (see FIG. 7). A wedge 168 is movablein block 74 by a screw 170 and contacts the tapered upper surface 172 ofcrimping head 162. Movement of wedge 168 will cause the rising orlowering of head 162. A second fixed crimping die 174 is secured toplate 22 and cooperates with crimping head 162. A spacer member 176separates the crimping dies 174 and 96. Adjacent to die 174 is themovable shear assembly 178, best shown in FIGS. 3, 5 and 8. The assemblycomprises a central support 180 having end portions 182 and 184 securedthereto. The assembly is mounted for vertical reciprocating movement andis biased upwardly by a spring 186. The upper surface 188 of support 180constitutes an impact surface and lies beneath one end 190 of crimpinghead 162. Upon descent of head 162 the end 190 will contact surface 188and drive the shear assembly downward. The crimping die 174 is receivedin a channel 192 formed in the support 180. A shear member 194 issecured to end portion 182 by screws 196 and a shear member 198 issecured to end portion 184 by screws 200. The crimping die 174 has shearfaces 202 and 204 at opposite ends of its upper surface. Shear member194 has a shear face 206 and shear member 198 has a shear face 208. Upondescent of shear assembly 178 the shear faces 202 and 206 cooperate tocut the insulating strip along line 210 and shear faces 204 and 208cooperate to cut the insulating strip along line 212. Located on theopposite side of shear assembly 178 from crimping die 174 is a shearmember 214 secured to block 110 by a pin 216. An L-shaped spring plate218 (see FIG. 3), secured to block 110 by screw 220, urges the shearmember 214 into engagement with the shear assembly 178 and also servesto prevent any rocking movement of the assembly 178. The shear member214 has lower surfaces 216 and 218 which cooperate with surfaces 220 and222 on end portions 184 and 182 respectively to limit the upwardmovement of assembly 178. A pair of shear faces 224 and 226 are formedin the upper surface of shear member 214. Shear member 198 has a secondshear face 228 and shear member 194 has a second shear face 230. Whenthe shear assembly 178 is moved downwardly, shear faces 226 and 228cooperate to sever one of the carrier strips 160 along line 232 andshear faces 218 and 230 cooperate to sever the other carrier strip 160.Support 180 is provided with bevelled surfaces 233 to provide apassageway for the discharge of the severed portions of the carrierstrips.

The transfer assembly E is best shown in FIGS. 1 and 3. A support 234 issecured to plate 22 by screws 236 and a double-action fluid cylinder 238is secured to support 234 by mounting screws 240'. An adjustable stopmember 242 is secured to the piston 244 of cylinder 238 by a set screw246. The stop 242 limits the rearward movement of piston 244 and has abifurcated end to receive a rod 248 secured to support 234. The rod 248serves to prevent any rotative movement of piston 244. A mounting block250 is threada bly secured to position 244 and held in adjusted positionby nut 252. The block 250 pivotally carries a pair of arms 254 and 256.The arm 254 is biased in a clockwise direction, as viewed in FIG. 1, bya spring 258 fastened at its ends to an ear 260 on arm 254 and an car262 on block 250. Arm 254 has an upstanding end portion 264 which servesto transfer a conductor 266 (see FIG. 2) from station A to station B.The other arm 256 is biased counter-clockwise, as viewed in FIG. 3, by aspring 268 fastened at its ends to an car 270 on arm 256 and an ear 272on block 250. The arm 256 has an end portion 274 having a groove 276adapted to fit over the tongue portion of a terminal and transfer theterminal from station A to station B. A pin 278 (see also FIG. 2)extends laterally from the arm 256 into the plane occupied by the shearblade 82. Upon retraction of arm 256 the pin 278 will contact blade 82and pivot the blade out of cutting position into the dotted lineposition shown in FIG. 6, for a purpose to be described later. A bracket280 is secured to bracket 24 by screw 282 and has an upper U-shapedportion 284. One leg 286 of portion 284 serves as a stripper for theconductor 266 upon raising the ram 72. The other leg 288serves the dualpurpose of stripping the terminal from crimping head 162 and also offorming a guideway 290 for the arm 256.

FIG. 3 shows the microswitches for controlling the operation of thedevice. A bracket 292 is secured to plate 22 by screws 294. A pair ofmicroswitches 294 and 295 are secured to bracket 292 by screws 296 andhave spring arms 298 and 299, the latter being hidden in FIG. 3,carrying rollers 300' and 301. The arms 298 and 299 depress switches 302for controlling the fluid flow to the various cylinders in a manner tobe described. A bracket 304 is secured to block 74 and carries switchcontacting cams 306 and 308. The cams 306 and 308 are adjustable inelongated slots 310 in bracket 304 (see FIG. 7) to vary the timing ofthe machine. A third microswitch 312 is secured to bracket 292 andcarries a spring arm 314 and a roller 316. A switch contacting cam 318is carried on stop member 242 of transfer assembly E. Upon reciprocationof the transfer cylinder piston 244 the cam 318 will contact roller 316and actuate microswitch 312 to control the flow of fluid into cylinder40 in a manner to be now described.

FIG. 10 shows schematically the fluid flow to the various cylinders inthe device. Fluid enters the system via a conduit 320 from a fluidsource (not shown) and enters solenoid controlled valve 322. The valve322 is movable between a first position shown in full lines and a secondposition shown in dotted lines. When valve 322 is in its first positionthe fluid will flow from conduit 320 into branch 324, which branchcommunicates with the rear of cylinder by means of artery 326 and withthe rear of cylinder 238 by means of artery 328. Branch 324 terminatesin a second solenoid controlled normally closed valve 330. When valve322 is in its second position the fluid will flow from conduit 320 intobranch 332, which branch communicates with the front of cylinder 120' bymeans of artery 334, with the front of cylinder 40 by means of artery336, and with the front of cylinder 238 by means of branch 332. Thevalve 330 is movable between a first position shown in full lines and asecond normally closed position shown in dotted lines. When valve 330 isin its first position, there is communication between branch 324 andartery 338 whereby fluid is introduced into the rear of cylinder 40,whereas when valve 330 is in its second position the fluid in branch 324is blocked and cannot enter cylinder 40. Valve 322 is controlled bymicroswitches 294 and 295 through suitable wiring 340 while valve 330 iscontrolled by microswitch 312 through suitable wiring 342.

The sequence of operation of the above fluid system will now bedescribed. Starting with the ram in the down position, the valves 322and 330 will be in their dotted line position so that fluid will be incommunication with the front of cylinders 120, 40 and 238 causing theirrespective pistons 124, 46 and 244 to be in their retracted position. Asthe ram ascends and nears its upper limit the cam 306 will contactroller 300 of microswitch 294 causing valve 322 to shift to its fullline position thereby affording communication between conduit 320 andbranch 324. Fluid in branch 324 will enter arteries 326 and 328 causingpistons 124 and 244 to move to their extended position. As piston 244moves to its extended position the cam 318 fixed to said piston willcontact roller 316 of microswitch 312 causing valve 330 to momentarilyshift to its full line position. This will cause fluid flow into therear of cylinder 40 and thereby cause the piston 46 to move to itsextended position. The valve 330 will then immediately return to itsnormally closed position. Upon the next descent of the ram 72, and nearthe lower limit of its stroke, the cam 308 will contact the roller 310of microswitch 295 causing valve 322 to shift back to its dotted lineposition whereby fluid will flow through branch 332 causing fluid toenter the front of cylinders 120, 40 and 238 whereby their respectivepistons will again be retracted.

FIG. 11 shows the completed product made by the method and apparatus ofthe present invention. A terminal 346 has its ferrule portion 348crimped to the bare wire 350 of a stripped electrical conductor 352. Aninsulating member 354 has its ends 356 crimped around the ferrule 348and conductor 352 to produce an insulated electrical connection.

The overall operation of the device will now be described. A strip ofterminals is placed in feed assembly C with terminal 66 in crimpingposition at station A. A strip of insulating members is placed in feedassembly D with the member at the lead end of the strip positioned tothe left of station B as viewed in FIG. 1. The ram 72 starts in the upposition so assemblies C, D and E are all in their extended position.The conductor 266 is placed in position at station A in the regionbounded by the ferrule of terminal 66 and the crimping head 80. Theoperator then starts the machine, by depressing a foot pedal or thelike, and the ram begins its descent. As the ram descends the crimpinghead 80 loosely engages the terminal 66, and the shear member 82 seversterminal 66 from the remainder of the strip. As the ram 72 continues todescend cam 308 contacts roller 301 Causing microswitch 295 to swing thevalve 322 into the dotted line position of FIG. 10. This causesassemblies C, D and E to move to their retracted position. Duringretraction the feed finger 60 will ride over the terminals on the strip,the arm 256 will ride over and onto terminal 66, and arm 254- will swingdownwardly under conductor 266. The head 80 then crimps the terminal 66to conductor 266. During a crimping operation there is a certain amountof extrusion which takes place as a result of the compressing of thematerial. Therefore, terminal 66 will elongate during crimping andprovision must be made to allow for this elongation. It is for thispurpose that shear blade 82 has a recessed portion 86 to partiallycompensate for this extruding effect. Also, the pin 278 on arm 256 willcontact the shear blade 82 during the retraction of arm 256 and swingthe blade out of cutting position to provide ample clearance for theelongation of the terminal and for the latters subsequent transfer. Theram next ascends causing earn 306 to contact roller 300 causingmicroswitch 294 to shift to its full line position of FIG. thus causingassembly D to feed an insulating member into position at station B andassembly E to transfer the crimped terminal and conductor into positionat station B above the insulating member. When the arm 256 isapproximately midway between stations A and B the end portion 274 willhave moved away from station A where it would have blocked the feed inof another terminal. At this point the cam 318 will contact roller 316causing microswitch 312 to momentarily swing valve 330 into its fullline position of FIG. 10 thus causing assembly C to feed terminal 68into position at station A. When the operator again depresses the footpedal or the like the ram 72 will descend causing blade 82 to severterminal 68 from the terminal strip and causing crimping head 80 tocrimp terminal 68 to a second conductor which has been positioned atstation A. In this embodiment the conductors are positioned by handalthough obviously there could be suitable mechanism for performing thisfunction. At the same time that terminal 68 is being crimped thecrimping head 162 is crimping the insulating member to terminal 66 andthe shear assembly 178 is severing the insulating member from its strip.The cycle is then repeated. It can be seen, therefore, that on eachdescent of the ram 72 two complete operations are performed whereby aninsulating member is crimped to the terminal which was crimped on thepreceding stroke of the ram. Thus there is no loss of time over a singlestage operation wherein both the terminal and insulating member would becrimped together. Also, by adjustment of head 162 relative to head 80 itis possible to independently vary the crimping pressure of theinsulation member relative to that of the terminal.

Changes in construction will occur to those skilled in the art andvarious apparently different modifications and embodiments may be madewithout departing from the scope of the invention. The matter set forthin the foregoing description and accompanying drawings is offered by wayof illustration only. The actual scope of the invention is intended tobe defined in the following claims when viewed in their properperspective against the prior art.

What is claimed is:

1. A method of forming an insulated electrical connection wherein anelectrical terminal having an open U-shaped ferrule-forming portion issecured to the stripped end of an insulated electrical conductor andwherein an open U-shaped insulating member is secured to the outersurfaces of said terminal and conductor, comprising the steps of feedingsaid terminal to a first crimping station, inserting the stripped end ofsaid conductor into said ferrule-forming portion of said terminal,crimping said terminal to said conductor, feeding said insulating memberto a second crimping station, transferring said terminal and conductorto said second crimping station in overlying relationship with saidinsulating member and crimping said insulating member about saidterminal and conductor.

2. A method of forming an insulated electrical connection wherein anelectrical terminal having an open U-shaped ferrule-forming portion issecured at a first station to the end of an insulated electricalconductor and wherein an open U-shaped insulating member is secured at asecond station to the outer surfaces of said terminal and conductor,comprising the steps of feeding a first strip of said terminals along afirst path whereby the terminal at the lead end of said first strip ispositioned at said first station, positioning an end of said conductorin the region of the ferrule-forming portion of said lead-end terminal,severing said lead-end terminal from said first strip, crimping saidterminal to said conductor to form an electrical and mechanicalconnection there-with, feeding a second strip of said insulating membersalong a second path to thereby position the member at the lead end ofsaid strip at said second station, transferring said connected terminaland conductor to said second station along a third path to therebyposition said terminal and conductor in the region above the bend insaid U-shaped insulating member, severing said lead-end insulatingmember from said second strip, and crimping said insulating member tosaid terminal and conductor.

References Cited UNITED STATES PATENTS 3,009,197 11/1961 Hahn 29-6303,164,861 1/1965 Munroe et a1. 185 3,283,398 11/1966 Andrew 292033,436,006 4/1969 Cole 264-23 JOHN F. CAMPBELL, Primary Examiner R. W.CHURCH, Assistant Examiner U.S. Cl. X.R.

